INTREPID INSTRUCTIONS - The Energy Conscious
Contents
1. BURNER BURNER PRESSURE HEAD SHUTTER RATE MODEL P N SINGLE STAGES py NOZZLE SETTING SETTING SETTING STAGE MFR PSIG NO T NO 1 80 ES 0 85 70 ES XL 30 40 5 48 0243 100 HAGO 140 1 35 1 2 80 B DELAVAN 130 m 40 R 40 F 5 48 0244 100 1 5 1 2 80 B DELAVAN 160 XL 50 R 40 F 10 48 0245 100 60 B DELAVAN T Air shutter and head settings shown are approximate ONLY See START UP page 7 NOTE For proper insertion into combustion chamber see figure 8 Figure 7A Riello 40 Series Figure 7B Riello 40 Series Model F 3 amp F 5 Model F 10 Electrode Setting Electrode Setting IMPORTANT THESE DIMENSIONS MUST BE OBSERVED AND VERIFIED 5 32 or 4 mm 5 64 to 7 64 or 2 to2 5 5 32 to 13 64 or 4 to 5 E IMPORTANT THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED 5 32 4mm Figure 8 For proper insertion into combustion chamber COMBUSTION CHAMBER XL 2000 BURNER DATA RIELLO continued REGULATION OF THE TURBULATOR AND AIR SHUTTER FOR PROPER COMBUSTION Turbulator Setting 1 Loosen nut 1 then turn the screw 2 until the index marker 3 is aligned with the correct index number 2 Retighten the retaining nut 1 TURBULATOR SETTINGS RIELLO 40 SERIES The numbers on the casting are there to denote the high and low end of the scale in all cases the first mark is Zero The air oil ratio depends on accurate setting of the turbulator disc2. Be careful when making this adjustment as an incorrect setting will result in an unsatisfactory installation See figure 9A and 9B Figure 9A Figure 9B SETTING THE AIR ADJUSTMENT PLATE Note For F 3 and F 5 models the air shutter is operated on a 120V 60 Hz motor the burner will not operate until the air shutter is in its fully open position and for F 10 model is operated by Hydraulic Jack see figures 10 A amp B NOTE 15 Regulation of the combustion air flow is made by adjustment of the manual AIR ADJUSTMENT PLATE 4 after loosening the FIXING SCREWS 3 amp 5 The initial setting of the air adjustment plate should be made according to page 13 The proper number on the manual AIR ADJUSTMENT PLATE 4 should line up with the SETTING INDICATOR 2 on the fan housing cover Once set the air adjustment plate should be secured in place by tightening SCREWS 3 and 5 For F 10 model manually open and release the hydraulic air shutter to ensure it has free movement The final position of the air adjustment plate will vary on each installation Use instruments to establish the proper settings for maximum CO and a smoke reading of zero Variations in flue gas smoke and temperature readings may be experienced when the burner cover is put in place Therefore the burner cover MUST be in place when making the final combustion instrument readings to ensure proper test results Figure 10A
3. 10 XL 2000 BASIC WIRING DIAGRAMS FOR Honeywell L7248L Io AMD NAR THUN without tankless heater CURRENT s Honewel 1 17224 24 VOLT with tankless heater L2 L1 FIELD CONNECTION THERMOSTAT OR WIRED TO L1 ON BECKETT pali ud d 3150 7505 PRIMARY IF EQUIPPED OTHER FACTORY MOUNTED BECKETT MODELL 7600A SXENGID NOZE LTE CONTROLS VALVE HONEYWELL R7184B UE IHE Service l BECKETT GENISYS AAA If equipped 7505P PRIMARY 11 IF EQUIPE MPINK BLACK BLACK FLAME D E lt FACTORY gt INSTALLED Q JUMPER RED FOR 7505 ul SINGLE A ZONE WIRING FOR MULTIPLE ZONE CIRCULATOR OR MULTIPLE ZONED CLE G dey SEE Adjusting CIRCULATOR METHOD E Settings SPACE HEATING ONLY R845 R845 R845 L7224C amp 172481 11 LEGEND FOR SINGLE AND MULTIPLE ZONED DIAGRAMS NEUTRAL FACTORY WIRING FIELD WIRING LINE VOLTAGE 24 VOLTS CIRCULATOR IM CIRCULATOR m ZONE 2 ZONE 3 ZONE 4 OTHER ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECION AS REQUIRED BY CODES CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED IS 1 4 IN TAB TERMINAL GROUNDING CONDUCTOR TWO GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE GREEN GROUND SCREW IN THIS BOX FIELD
4. INLET AIR VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE Figure 3d Appliances located in confined spaces All air from outdoors through ventilated crawl space and outlet air to ventilated attic See Table 2 2 4 The opening size recommendation just given is for guidance only It is the installers responsibility to provide air for combus tion and ventilation to all appliances under all operating con ditions for each installation See NFPA 31 latest edition for more specific details INSTALLING CONTROLS AND ACCESSORIES ON BOILER UNITS Notes Jacket must be installed on boiler units prior to installa tion of trim WATER BOILER TRIM see page 2 figures 1 and 2 for tap ping locations WATER PIPING FOR HOT WATER HEATING BOILERS NOTE On knocked down boiler only jacket may be installed after supply piping connection but must be installed prior to adding trim and piping returns and drain valve CIRCULATING SYSTEM A FORCED CIRCULATION hot water heating system Use the top tapping as supply tapping and use the front or rear bottom tappings for the return B A FLOW CONTROL VALVE will prevent gravity circula tion and is required when an external tankless heater an indirect water heater or multiple circulators are installed Il AIR CONTROL SYSTEMS A DIAPHRAGM TYPE COMPRESSION TANKS are used to control system pressure in an AIR ELIMINATING SYSTEM an automatic air vent is used to REMOVE air from the system water
5. Check chimney condition Existing chimneys and stacks may have deteriorated with out repairs their use would be hazardous Before connect ing to an old chimney or stack Clean it Inspect it thoroughly Remove obstructions Replace worn sections of metal stacks Seal bad masonry joints Repair damaged lining C Where more than one appliance vents into a common chimney the area of the common breeching should at least equal the area of the largest appliance flue plus 5096 of the additional flue areas D Breeching area must not be reduced at connection into chimney Breeching must be inserted into but not beyond inside of chimney liner E Chimney height shall extend at least 3 feet above where it passes through the roof of the building and at least 2 feet above any ridge within 10 feet of the chimney F The use of a vent cap where permitted by code gives additional protection against adverse wind conditions and precipitation G Flue Connection Connect flue pipe between top of boiler and chimney Horizontal sections of flue pipe must be pitched upward to the chimney at least 1 4 per foot Flue must be inserted into but not extend beyond the inside wall of the chimney flue Install draft regulator in flue pipe as shown in figure 3 AIR SUPPLY AND VENTILATION see 31 latest edi tion Sufficient air for combustion and ventilation in the boiler room must be provided Failure to
6. Model F 3 F 5 Air Adjustment Figure 10B Model F 10 Air Adjustment Slant Fin Corp 2008 SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 ci nf g 7 FAX 516 484 5921 Canada Slant Fin 1 Mississauga Ontario www slantfin com
7. or overfire draft of 0 02 W C can not be obtained check for proper sealing between sections between the hinged burner mounting door and front section around burner blast tube and around flue collector and collar If seal is not satisfactory reseal with furnace putty or silicone with a temperature rat ing of at least 400 F All safety precautions indicated on material package must be followed G Once burner and draft have been set up then smoke CO and stack temperature should be checked and recorded If smoke is greater than trace review the burner instructions and replace the nozzle if necessary Normal smoke to be expected is zero to a trace H Make sure that the observation port cover is closed and the screw is tightened CLEANING AND FILLING A NEW WATER BOILER There are a number of commercial preparations available from your distributor for cleaning and for corrosion protection conditioning the internal waterside surfaces of boilers Follow the preparation manufacturer s instructions DANGER Use CAUTION when handling chemicals and draining hot water from a boiler Scalding water and or chemicals can cause permanent injury to the skin eyes and respiratory system Filling and venting the water boiler after cleaning Refill the system with fresh water Bring water temperature to at least 180 F promptly Circulate water through entire system Vent the system including the radiation The boiler is n
8. External Low Limit After 60 seconds without any button inputs the control will automatically return to the RUN mode DISPLAY In the RUN mode the Aquastat will flash bt boiler temp followed by the temperature i e 220 followed by F or C To read boiler settings press the key to read the parameter of interest For example press High Limit HL is displayed followed by a three digit number i e 220 followed by F or C Pressing the button again on L7224 models will display the Low Limit LL followed by a three digit number and the corresponding degree designator After approximately 60 seconds without any key presses the display will enter a dim display mode To return to the bright display mode simply press any key DESCRIPTION Boiler Temperature b t High Limit H L Low Limit L L Low Limit Differential L dF Local Thermostat Status c Enviracom Thermostat Status t E Error Code E rr Degrees Fahrenheit OF Degrees Celsius OF Error Code Cause Action Alarm electrical noise or frequency out ofrange Hardware faule replace conuoler 1838 _ Eme Waming Fuse check ECOM wires replace fuse Warning EEPROM HL LL Hdf Ldf reset to default values Repeated B1 fault voltage present at B1 when output is turned off check B1 wiring voltage 25 Err9 Warning Outdoor Reset System failure communication to Outdoor Reset Module
9. See figures 5 and 6 If system pressure needs further control add an addi tional tank or install a larger capacity tank The automatic air vent should be installed in the top of a ALTERNATE 9 i L COMPRESSION TANK PRESSURE REDUCING AUTOMATIC VALVE AIR VENT CIRCULATOR DIAPHRAGNM COMPRESSION 5 MAKE UP RELIEF WATER FEED VALVE RETURN ALL PIPING AND CIRCULATOR MUST CLEAR SWING OF BURNER DOOR Figure 5 Air Eliminating System or Alternating Collecting System XL 2000 the boiler as in figures 5 and 6 and at radiation high points see C B CONVENTIONAL COMPRESSION TANKS non diaphragm type are used to control system pressure in an AIR COLLECTING SYSTEM Within the system after initial start up and venting air is collected in the tank and acts in contact with the water to control pres sure see dashed area in figure 5 and paragraph E Air is not vented from this system except at radiation high points see C If system pressure needs further control add another tank in parallel with the original tank or install a large capacity tank Locate the tank at the inlet end of the pump near the boiler See figure 5 C HOT WATER RADIATION VENTING Manual air vents should be installed at the top of all drops where pip ing goes downward Air must be vented or purged from all zone lines to permit proper system heating D PUMP LOCATION Locating low head pump s on return to
10. do this will result in poor combus PITCH UP 1 4 PER LINEAR FOOT DO NOT INSTALL DRAFT REGULATOR HERE S BAROMETRIC DAAFT CONTROL DRILL 1 4 HOLE TO MEASURE DRAFT SMOKE CUOESS AND STACK TEMPERATURE MAINTAIN W C DRAFT iOVER FIRE Figure 3 Barometric Draft Regulator Location tion heavy sooting and health hazards Any oil fired boiler must have a steady draft and an ample supply of combustion air at all times during firing If air supply or chimney draft is unreliable and overfire draft will change unpredictably DO NOT vent this boiler to the same chimney flue used by a fireplace or coal or wood burning furnace or boiler The draft produced by solid fueled devices varies tremendously between high fire and low fire In modern weather stripped energy saving buildings or older buildings which have been modified similarly natural infiltra tion may not supply enough air for combustion particularly if other fuel burning appliances exhaust fans or draft inducers are competing for the same air supply Fireplaces other solid fuel burning appliances and exhaust fans consume great quantities of air if air supply is not ample such an appliance Draft is negative or suction pressure XL 2000 will create a downdraft in the oil fired boiler flue This can cre ate a hazardous condition Flue gases can be sucked out of the chimney through the vent regulator into the living space DO NOT
11. hydronic systems Consult glycol manufacturers for sources of propylene glycol DO NOT USE ETHYLENE GLYCOL BECAUSE IT IS TOXIC OIL BURNER Inspect and clean annually and following any period of improper operation Recheck and adjust settings as speci fied for burner model and nozzle size Set burner air and draft regulator using test instruments to obtain recommended CO and draft without smoke See the Burner Data page in this manual that corre sponds to the burner installed IV GENERAL MAINTENANCE These operations are recommended to be performed at regular intervals A BOILER HEATING SURFACES clean off all coatings found Reseal covers B BOILER CONTROLS check contacts settings correct functioning C PIPING check piping and accessories for leaks D CHIMNEY or STUB VENT BREECHING check for obstructions and leaks E COMBUSTION AIR TO BURNER check for continued POSITIVE supply of air as required Air needs are greatest in coldest weather Refer to AIR SUPPLY page 3 F WATER SYSTEM check 1 System to be full of water and pressure to remain stable between 12 psi and 25 psi 2 Air control system noise and air binding in radiation should not occur 3 Water lines slightest leaks should be corrected G BOILER ROOM AIR SUPPLY air vents should be open and free of obstruction See page 3 T Aflue brush 2 1 4 dia is supplied with boiler Replacements are available from dealer or hardware stores
12. with water 317 405 493 581 Includes burner circulator and controls B The XL 2000 Boiler has full wet base sections which sur round fire box for maximum heat absorption of burning fuel and low floor temperature C If boiler is to be located over buried conduit containing electric wires or telephone cables consult local codes or the National Board of Fire Underwriters for specific require ments MINIMUM CLEARANCE Provide accessibility clearance of 24 from surfaces requiring servicing top and front and 18 on any side requiring pas sage The boiler shall be installed with the following MINIMUM clearances from combustible materials A CHIMNEY CONNECTOR 18 B BACK AND SIDES 6 EXCEPT as limited by 18 clear ance from chimney connector NOTE Except in closets and alcoves clearances above in A and B may be reduced by providing forms of protection as specified in NFPA 31 latest edition PITCH UP 14 FER LINEAR FOOT DOUBLE SWING BAROMETRIC DRAF CONTROL DO NOT INSTALL DRAFT FEGLILATOR HERE DRILL 144 HOLE MEASURE DRAFT SMOKE CO AND STACK TEMPERATURE MAINTAIN DOF W C DRAFT OVER FIRE iT TR ee CHIMNEY REQUIREMENTS see 31 latest edition A The chimney must be constructed in accordance with all local applicable codes and the National Board of Fire Underwriters See boiler models and rating table shown on page 2 for chimney sizes B
13. C DISK BOILER MODEL NO 2 OIL AND SETTING SED NO AIR BAND DIAMETER GPH TYPE PSIG SETTING NO INCHES XL 20 4 AFG 0 65 80 A DELAVAN 100 Blank Closed 33 SF2201 XL 30H AFG 70 W DELAVAN Blank Closed 23 SF2204 XL 30 1 00 1 00 80 W DELAVAN 100 23 4 1 15 1 00 80 W DELAVAN 130 o 23 4 XL 40H AF 1 25 1 25 80 W DELAVAN 100 None SF2205 XL 40 1 35 1 35 80 W DELAVAN 100 NUN None m m 1 55 1 35 80 W DELAVAN 130 10 None XL 50 1 80 1 75 70 B DELAVAN 105 10 None m NOTES 1 Blank closed air band for XL 20 2 slot band for XL 30 4 slot band for XL 40 and 8 slot air band for XL 50 2 See PRECAUTIONS BEFORE STARTING OIL BURNERS and START UP on page 7 and burner figures on this page 3 All burner models shown are single stage 4 XL 20 is supplied with a low fire baffle Beckett No 31760 installed SEE TABLE FOR CORRECT SETTINGS SHUTTER ADJUSTMENT SHUTTER OPENS WHEN ROTATED CLOCKWISE EXAMPLE SHOWN AT N 6 POSITION EMBOSSED AIR BAND ADJUSTMENT OPENS WHEN ROTATED CLOCKWISE EXAMPLE SHOWN AT N 2 POSITION ADJUSTMENT MOUNTING 3 32 GAP FLANGE STATIC DISK ELECTRODE 1 1 8 TOP VIEW OF GUN ASSEMBLY NOZZLE ELECTRODE ADJUSTMENTS BECKETT 14 XL 2000 BURNER DATA RIELLO BURNERS FOR PACKAGED BOILERS ONLY RIELLO R 40 SERIES W SHORT TUBE NOZZLES APPROX RELLO SLANTIFIN OES om pump approx
14. ION REQUIRED column at right See NOTE 2 below Confined space NONE Provide air from outdoors directly through a permanent out side wall opening or openings with a free open area of not less than 1 sq in per 4000 Btu hr of TOTAL input of ALL fuel burning appliances in the building See Note 1 and 3 The confined space shall be provided with two permanent air openings one near the top of the enclosure and one near the bottom EACH opening shall have a free air opening of not less than 1 sq in per 1000 Btu hr of TOTAL input of ALL fuel burning appliances within the enclosure The two openings shall freely communicate with the interior areas of the building which in turn would have to have adequate infiltration of air from outdoors See Notes 1 3 and Figure 3a a Air from the outdoors shall be provided to the confined space by two permanent openings one in or near the top of the enclosure space and one in or near the bottom The openings shall communicate directly or by means of ducts with outdoors or to such spaces crawl or attic that freely communicate with outdoors See figures 3b 3c and 3d b Where directly communicating with outdoors or by means of vertical ducts each opening shall have a free area of not less than 1 sq in per 4 000 Btu hr 35 sq in per gal per hr of total input rating of all appliances in the enclo sure If horizontal ducts are used each opening shall have a free area of no
15. Manual sup plied with burner If burner is not mounted as received mount to boiler placing flange over mounting studs Use gasket between flange and boiler Distance between flange and nose of burner must be as shown on pages 11 and 12 Check to see that nozzle and settings are as given in burner data tables pages 11 and 12 OIL SUPPLY PIPING Install the oil tank or tanks and piping from tank to burner Follow local codes and practices INSTALLATION OF OIL BURNING EQUIPMENT NFPA 31 latest edition and the instruction sheet attached to the oil burner pump A one pipe system should be used for gravity fed fuel systems and for lift systems where the total lift is less than 8 feet Where the total lift is greater than 8 feet a two pipe system must be used In some instances local codes may require a two pipe system for below grade fuel oil tanks Be sure to set up the fuel oil pump for the piping system used follow the instructions attached to the pump Be sure to include a good quality low pressure drop fuel oil filter in the supply line from the tank This is necessary especially at low fuel oil flow rates small nozzle sizes to prevent nozzle plugging Fuel oil shutoff valves should be installed at the burner on the supply and return if two pipe to facilitate servicing See Slant Fin publica tion on one pipe and two pipe fuel oil systems WIRING THE BOILER see National Electric Code ANSI NFPA 70 latest edition A The wiring
16. REAR DRAIN OR EXPANSION TANK TAPPING Figure 1 Figure 2 F SUPPLY CIRCULATOR FLANGE VEN TIE SPAN SIOM TAME TAPPING COMBINATION DALY ELECTRICAL CONDUIT COMBINATION CONTROL POWER CONECTION JUNCTION BOX OBSERVATION HINGED BILIHNER PORT COVER MOUN TING DIA HE 112 RETURN PRIMARY CONTAGL RELAY HINGED MOUNTING DOCK TABLE 1 Ratings and Dimensions AHRI BURNER D O E AHRI NINE SIZE CAPACITY HEATING WATER BOILER OILINPUTt CAPACITY NET RECT 1 D ROUND nde MODEL MBH RATING X HEIGHT4 X HEIGHT FLANGE D NO WATER MBH inxinxft inxft AFUE NPT 91 000 8 x8x15 119 000 8 x8x15 8 x8x15 DIMENSIONS inches O E 140 000 XL 2000 CIRCULATOR APPROX OVERALL LENGTH Standard working pressure 30 psi All 161 000 175 000 189 000 217 000 252 000 280 000 8 x8x15 8 x8x15 8 x8x15 8 x8x15 8 x8x15 8 x8x15 NN N OOQ are properly adjusted to produce 13 boilers hydrostatically tested A S M E t Nominal clay tile liner dimensions For forced hot water heating systems where the boiler and all piping are Water boiler models XL 30 and larger have two firing rates The boiler is fac located within the area to be heated the boiler may be selected on the basis of D O E capacity output The net AHRI output ratings shown are based on an allowance f
17. WIRE A GROUNDED CONDUCTOR TO THIS SCREM TOGETHER WITH THE TWO GREEN FACTORY CONNECTED GREEN GROUND WIRES OPTIONAL HYDROSTAT MODEL 3150 IS EQUIPED WITH AN INTERNAL LOW WATER CUT OFF ZONE WIRING DIAGRAM Tir wn qe Ger TONAL MULTIPLE ZONED ZONE VALVE METHOD HYDROSTAT 3150 CONTROLS USING HONEYWELL V8043F OR ERIE 765 FOR TANKLESS HEATER APPLICATIONS HOT ELECTRICAL POWER SUPPLY B m OVERLOAD PROTECTION er MEME 53i run T822D NEUTRAL AS REQUIRED BY CODES TRANSFORMER __ pev _ I TO OTHER SAFETY PRIMARY E 4 q s 120V AC 60Hz Md EN IR FIELD CONNECTION 5 T JUNCTION BOX FACTORY MOUNTED 9 Q CONNECT TO T T ON L8148A AQUASTAT TO x OTHER ZONES 43 0864 xNote Total load not to exceed 8 amp full load for circuits shown W V XL 2000 11 FOR L7224C OR L7248L ADJUSTING SETTINGS To discourage unauthorized changing of Aquastat settings a procedure to enter the ADJUSTMENT mode is required To enter the ADJUST MENT mode press the UP DOWN and buttons simultaneously for three seconds Press the button until the feature requiring adjustment is displayed HL_ High Limit LL_ Low Limit L7224 only Ldf Low Limit Differential L7224 only pte ELL_ External Low Limit 1 72481 only Then press the UP and or DOWN buttons to move the set point to the desired value to change between F and or to enable On or dis able Off the
18. boiler is only acceptable in residences of one or two stories See figure 6 The pump location shown in figure 5 is required in large multi story building instal lations especially when high head pumps are used and is also recommended for all applications E A conventional compression tank may be connected directly to the 1 2 tapping on the boiler see Alternate Compression Tank figure 5 IMPORTANT Hot water heating systems containing high water volume such as would occur with cast iron radiation require special care with air elimination The circulator pump should be located on the boiler supply pipe and the expansion tank and air scoop should be located near the pump suction as shown in figures 5 and 6 For alternate circulator pump location on return for low head pumps and one or two story buildings ONLY see figure 6 AUTOMATIC A IR VENT SUPPLY MAKE UP WATER FEED RETURN PRESSURE ae DIAPHRAGM COMPRESSION LOW HEAD CIRCULATOR ALL PIPING AND CIRCULATOR MUST CLEAR SWING OF BURNER DOOR Figure 6 Alternate Air Eliminating System XL 2000 DOMESTIC HOT WATER For Indirect fired storage water heater application see Slant Fin publication WH 10 Sizing Guide WH SG and Installation manual WH 40 The installation manual includes several control systems and relay centers for space and domestic water heating in addition to plumbing INSTALLING THE BURNER See Burner Data pages 11 and 12 and Burner
19. diagrams for the burner and boiler may be found on page 10 B 24 volt control wiring should be approved Safety Circuit wire protected as needed C Power supply wiring to the burner must be 14 gauge as required and should have a properly fused disconnect switch 120 volt wiring to pumps and safety controls must also be 14 gauge Wire must be enclosed in approved conduit D The wires supplying power to the burner MUST go through the quick disconnect plugs provided with the boiler E All wiring must be installed in compliance with the National Electric Code or any local or insurance codes having juris diction VENT PIPING AND DRAFT REGULATOR see NFPA 31 latest edition A Vent connectors must be the same diameter as the boiler flue collar See page 2 B Vent pipes and breeching must be pitched upward a mini mum of 1 4 per foot C Connect vent pipe to the chimney using as few elbows as possible and as short as possible within NFPA 31 or authority D Horizontal vent connector into the chimney should not be inserted beyond the inside wall of the chimney E Install barometric draft regulator on horizontal breeching near chimney with hinge horizontal and face vertical condi tions permitting as in Figure 3a See Figure 3b as a second choice See manufacturer s instructions packed in carton with barometric draft regulator F If two or more appliances are used on the same chimney see CHIMNEY page 3 G Make up all join
20. lant Fin L 2000 OIL FIRED WATER BOILERS NO 2 OIL INSTALLATION AND OPERATING INSTRUCTIONS SAFETY WARNING KEEP BOILER AREA CLEAR AND FREE FROM COM BUSTIBLE MATERIALS GASOLINE AND OTHER FLAM MABLE VAPORS AND LIQUIDS FAILURE TO ADHERE TO ABOVE SAFETY WARNING MAY RESULT IN PERSONAL INJURY OR DEATH AND PROPERTY DAMAGE CONTENTS oss 2 au REA PAGE Ratings and Dimensions 2 Installation Requirements Boiler Location 1e uar d zone Ris xA uA 3 e qc 3 Chimney Requirements 3 Air Supply and Venting 3 4 Controls and Accessories 5 Piping Tor Water Units 5 Installing Burner CIL Supply PIDING ROSCR E oe 5 Wiring the Boiler 5 Vent Piping and Draft Regulator 5 Operating Instructions Precautions Before Starting 7 IMPORTANT The installation of this equipment must con Start up ees s 7 form to the requirements of the authority having jurisdiction Cleaning and Filling New Water Boiler 8 or in the absence of such requirements to the Installation of Care and Maintenance Oil Burning Equipment ANSI NFPA 31 latest edition and to Extended Shutdown the National Electrical Code ANSI NFPA 70
21. latest edition Freezing Protection The installation must also conform to the additional require Oil Burner ments in this Slant Fin Instruction Manual Where there is any General Maintenance difference the more stringent requirement shall govern Wiring Diagrams ince RS cut ag hot AC ee Burner Dala suo sw VA ERROR EHEN can ewes ee Alam us In addition where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 latest edition THIS MANUAL MUST BE LEFT WITH OWNER AND SHOULD BE HUNG ON OR ADJACENT TO THE BOILER FOR REFERENCE Pu we ell CERTIFIED IMPORTANT This boiler must be installed serviced and repaired by a trained experienced service technician licensed for the installation and servicing of oil burning hot water heating system equipment or otherwise qualified by the authorities having jurisdiction over the installation Printed in U S A 1111 Publication No XL 40 Part No 48 0090 Revision D 1 4 PRESSURE amp TEMPERATURE TAPPING TOP VIEW 1 2 NPT CONTROL TAPPING OE TAVAVAUAVAVAVATAVAVAVATATAVATATATATI 3 4 RELIEF VALVE TAPPING MUU UUM 1 1 2 SUPPLY 1 1 2 ALTERNATE T n REAR RETURN TAPPING 1 2 AIR VENT 3 4
22. lost Outdoor Reset Module failure multiple outdoor temperature sensors detected on the bus or outdoor temperature sensor failure Check EnviraCOM wiring 1 2 3 check sensor wiring Err 10 Warning Boost Failure Boost Mode active at least once per cycle for the last 60 150 consecutive cycles Check Outdoor Reset curve settings Err 11 DHW Module Sensor failure communication to DHW Module lost DHW Module failure or 146 147 temperature sensor failure Check EnviraCOM wiring 1 2 3 check sensor wiring 148 Warnings are generated to enunciate the system is not operating optimally but the Aquastat is still operating and maintaining boiler temperature In the instance where an Outdoor Reset Module is used the warnings may indicate a reset curve setting error one or more features is not running optimally and the Aquastat is reverting to default settings or has stopped running the Outdoor Reset algorithms The warnings are cleared when the issue s is resolved P To clear Err 8 condition depress and hold all three user keys simultaneously for 60 seconds Err 8 condition clears and display returns to normal Err 8 condition is designed to catch welded relays on the Aquastat and will normally only occur near end of life for the control If Err 8 condition has occurred early in the controls life be sure to check for voltage feedback to B1 when B1 should be off and check current draw on b terminal to be sure oil burner is not draw ing excessi
23. on protection conditioning to the boiler water in the heating system There are a number of com mercial heating system preparations available from your distributor Follow the preparation manufacturers instruc tions C To clean the fireside boiler surfaces first shut down burner by disconnecting all electrical power to the burner by turning OFF the OIL BURNER EMERGENCY SWITCH of this boiler in order to perform the following work in 1 through 10 below 1 Remove the flue pipe from the boiler flue collar and clean thoroughly 2 Inspect the entire vent connector back to the chim ney and clean if necessary 3 Inspect the chimney for soot debris and other unsafe conditions of the chimney and take the necessary action 4 Remove the flue collector by first removing the top jacket panel The flue collector is held in place by two hex 1 4 20 screws Remove the screws and carefully remove the flue collector Try not to disturb the flat fiberglass rope under the flue collector 5 When necessary to clean the combustion chamber you must first CLOSE the suction valve and return valve if two pipe Then disconnect the oil lines from the burner The flexible electric conduit connected from the junction box on the boiler to the burner via a plastic connector must be disconnected from the burner by grasping the plastic half of the connector closest to the flexible conduit and gently pulling it in the direction of the conduit until it is disc
24. onnected Remove the single 3 8 16 hex head screw on the LEFT side of the swinging door You will need a 9 16 drive socket Open the door to completely expose the combustion chamber for thorough cleaning and for inspection of target wall blanket provided in certain models see rating plate main cast iron burner door insulation and burner door fiberglass sealing rope If combustion chamber parts above are badly deterio rated then replace with original factory parts avail able at your distributor XL 2000 6 Use the flue brush to clean the pinned flueways between the sections T wire brush may be used to remove any carbon accumulation that may have developed in the combustion chamber Vacuum the loose soot and debris from the boiler 7 Inspect the burner combustion head Clean if nec essary and make sure all the adjustments are cor rect See burner data pages for the burner installed Replace oil nozzle with new one and readjust electrodes To insure proper burner opera tion ONLY THE NOZZLES SPECIFIED IN THIS MANUAL OR ON THE BURNER LABEL SHOULD BE USED FOR REPLACEMENT 8 Protect all of the fireside surfaces by swabbing with neutral mineral oil 9 Close main cast iron burner door door on which burner is mounted Make sure that the entire seal fiberglass rope is making good contact with the boiler casting when replacing 3 8 16 x 1 long hex head bolt and tightening 10 Check the flue collector seal This is the fla
25. operate this boiler and a solid fuel burning appliance at the same time unless the solid fuel burner is provided with its own outside air supply See Table 2 Provisions for Combustion and Ventilation Air Supply for determining need and method of providing air for combustion and ventilation If fly screen must be used over air supply openings areas cal culated should be doubled the screen should be inspected and cleaned frequently to maintain free air flow Protect air openings against closure by snow debris etc Openings such as doors or windows if used must be locked open TABLE 2 Provisions for Combustion and Ventilation Air Supply See NFPA 31 latest edition for more detailed information UE Boiler Location Air Supply Action Required Unconfined space Unconfined space Confined space Is there sufficient air for combus tion by natural infiltration see NOTE 1 Test below If there in NOT sufficient air for combustion by natural infiltration due to tight construction or other conditions then it REQUIRES AIR FROM OUTDOORS SEE ACTION REQUIRED column at right See Notes 1 and 2 below If there is sufficient air for combus tion from within building but it comes from outside of the confined space see ACTION REQUIRED column at right See Note 1 below If there is NOT sufficient air for combustion due to tight construc tion or other conditions it REQUIRES AIR FROM OUT DOORS SEE ACT
26. or piping and pickup of 1 15 water or 1 33 steam D O E tory shipped at the lower firing rate To obtain the higher firing rate refer to the XL 2000 boiler installation instructions for the appropriate field adjust ments models have only one firing rate capacity output is divided by the allowance to obtain net rating The Slant Fin Oblong flue collar Fits 6 dia vent connectors Technical Service department should be consulted before selecting a boiler All dimensions subject to normal manufacturing tolerance for unusual piping and pickup requirements such as intermittent system oper ation extensive piping etc Ratings apply to the use of light oil at 140 000 Btu per gallon and apply only NOTE All boilers under 300 000 Btuh 87 9 kw input are tested and rated for capacity under the U S Department of Energy D O E Test Procedures for Boilers when burner models listed on pages 11 and 12 of this manual are used and XL 2000 THE INSTALLATION INSTRUCTIONS IN THIS MANUAL ARE ABBREVIATED SEE THE FRONT COVER OF THIS MANUAL FOR REFERENCES TO CODES AND STAN DARDS BOILER LOCATION Provide a level solid foundation for the boiler Location should be near the chimney so that the Flue Pipe Connector or Breeching to the chimney is short and direct A The foundation must be capable of supporting the weight of the boiler when filled with water Boiler Approximate Total Weight of Boiler Size Assembly filled
27. ow ready to be put into service or on standby If brand name air control devices are used venting instructions furnished with the devices should be followed muoou2 WATER CONTENT OF BOILER GALLONS XL 20 XL 30 XL 40 XL 50 VOLUME OF WATER IN STANDARD PIPE OR TUBE Nominal Inches Standard Steel Pipe Inside Schedule Diameter No Inches Type L Copper Tube Gallons per Lin ft Gallons per Lin Ft Inside Dia Inches Pipe Size XL 2000 Ill Safety check for control system High limit control test Set thermostat high enough for boiler water temperature to reach high limit control setting When this temperature is reached the high limit switch should open and the burner should shut off automatically If the high limit does not operate to shut off the burner the high limit or the wiring is faulty Repair or replace immediately CARE AND MAINTENANCE EXTENDED SHUTDOWN CLEANING OR REMOVAL OF BOILER FROM SERVICE DANGER Use CAUTION when handling chemicals and draining hot water from a boiler Scalding water and or chemicals can cause permanent injury to the skin eyes and respiratory system A Shut down burner by disconnecting all electrical power to the burner by turning OFF the BURNER EMERGENCY SWITCH of this boiler After shutting down burner while the boiler is still hot 180 F to 200 F drain water from the bottom of the boiler until it runs clear B Provide corrosi
28. t less than 1 sq in per 2 000 Btu hr 70 Sq in per gal per hr of total input of all appliances in the confined space See Figures 3b 3c and 3d 1 Test for sufficient air for combustion by infiltration by running this boiler for 30 minutes under all of the following conditions and at the same time a all doors win dows and other like openings must be closed b all fuel burning appliances should be FIRING c all exhaust fans and clothes dryers turned ON At the above conditions the CO smoke and draft readings must be normal between 11 and 13 smoke between ZERO and a TRACE draft between 02 W C and 04 W C negative pressure 2 Aside from tight construction some of the conditions that steal air for combustion from a boiler are other fuel burning appliances exhaust fans and clothes dryers 3 Generally louvers made of wood have a free open area of 2096 and those made of metal have a 6096 to 7096 free open area Screens also reduce the open area of the louvers XL 2000 Figure 3a Appliances located in confined spaces Air from inside the building See Table 2 2 3 VENTILATION LOUVERS EACH END OF ATTIC INLET AIR DUCT ENDS 1 FT ABOVE FLOOR Figure 3c Appliances located in confined spaces Air from out doors through ventilated attic See Table 2 2 4 Figure 3b Appliances located in confined spaces Air from out doors See Table 2 2 4 VENTILATION LOUVERS EACH END OF ATTIC
29. t rope seal on top of the heat exchanger The rope must be in place adjacent to the long bosses on front and rear sections and adjacent to the short bosses on the intermediate sections The rope should be directly under the flue collector flanges when the flue collector is replaced Use the two 1 4 20 x 3 4 washer hex head screws to fasten the flue collector In order to assure a proper seal be sure that the flue collector is compressing the flat rope and not hanging up on the section bosses Tighten the two SCrews D If boiler room is damp provide ventilation PROVIDING PROTECTION FOR FREEZING Anti freeze is sometimes used in hydronic heating sys tems to protect against freeze up in the event of power failure or safety control shutdown when the building is unoccupied It should be recognized that unless the building is kept above freezing temperature by some means the plumbing system is not protected PROPYLENE GLYCOL is used in the quick freeze food industry it is practically non toxic Its use may be permit ted when indirect water heaters are used When anti freeze must be used inhibited propylene glycol is recom mended Useful information on the characteristics mixing proportions etc of glycol in heating systems is given in Technical Topics No 2A available from the Slant Fin web site go to http slantfin com Go to library select current literature select boiler model See related topics and select antifreeze and
30. tion port cover swing the cover open and tighten the screw See the burner instructions for bleeding air etc Step away from the boiler and start the oil burner C IMMEDIATELY set burner air bands to obtain a bright fire without smoke or oil stain Set the DRAFT REGULATOR to obtain 02 overfire draft Take draft reading through slot in observation door after first closing the observation door D Tighten the observation door screw Allow the burner to fire for at least one hour total firing time to bake out the volatile binders in the combustion chamber before taking final com bustion readings E By alternate adjustment of the barometric draft regulator the burner air regulation and head regulation devices whichever apply set for zero to a trace of smoke and 12 CO Then open the air bands or shutter whichever apply an additional 1 8 This should result in zero smoke with NO raw oil on the smoke paper and a smooth light off DO NOT ATTEMPT TO SET FIRE BY EYE Flame retention burners may appear efficient and smoke free from an inefficient 7 up to an overly high 14 CO However a very low CO can also result in poor ignition and raw unburned oil entering the fire box At very high COs any slight decrease in air flow for any reason will cause incomplete combustion with high smoke and dry soot formation in the fire box If smoke reading is satisfactory but can not be increased to a satisfactory level 12
31. ts with minimum air leaks secure with sheet metal screws PRECAUTIONS BEFORE STARTING OIL BURNER Make a positive check of A through F before starting burner A Boiler and system are full of water All air is vented from system See below B All wiring is completed See page 10 C Oil supply is connected to the burner nozzle is installed correctly oil valve is open at tank Main cast iron door on which burner is mounted is bolted shut and fiberglass rope seal is making good contact Smokepipe is connected to chimney All combustible materials are cleared away Combustion air supply is provided See page 3 Burner settings are adjusted as per pages 7 8 11 and 12 and as shown on boiler jacket I mm WARNING NEVER OPERATE any natural draft boiler XL 2000 boiler is a natural draft boiler with zero draft or overfire pressure early failure of the burner nozzle and chamber is inevitable if you do Use a draft gauge and make sure that overfire draft is 02 to 04 during all operating conditions Draft is negative or suction pressure START UP COMBUSTION TEST INSTRUMENTS MUST BE USED A Make sure the boiler is installed and wired properly and is full of water B The observation port cover is mounted on the hinged burner mounting door see figure 2 on page 2 NEVER touch the port cover or any surrounding surfaces with hands They may be HOT Use tools Loosen the screw that fastens the obser va
32. ve current Err 8 condition will keep repeating if B1 fault is not cleared 12 XL 2000 BURNER DATA CARLIN BURNERS FOR PACKAGED BOILERS ONLY FIRING OIL PUMP A APPROXIMATE SHUTTER RATE ANGLE PRESSURE APPROXIMATE AIR BAND NON BOILER CARLIN BURNER NO 20IL SIZE AND SETTING HEAD SETTING OPENING ADJUSTABLE MODEL MODEL 2 3 GPH GPH TYPE 1 XL 20 99 FRD 0 65 0 65 70 A DELAVAN 100 50 Closed 71399 00F XL 20 0 65 70 W DELAVAN 100 50 Closed A A XL 30 99 FRD 1 00 1 00 70 DELAVAN 100 80 Closed 71399 00F XL 30 1 15 1 00 70 DELAVAN 130 90 Closed XL 40 99 FRD 1 35 1 35 60 W DELAVAN 100 50 Closed 71399 00F XL 40 1 55 1 35 60 W DELAVAN 130 65 Closed XL 50 99 FRD 1 80 1 75 60 B DELAVAN 105 71399 00F XL 50 2 00 1 75 60 B DELAVAN 130 NOTES 1 Single slotted air band for XL 20 and XL 30 double slotted air band for XL 40 and XL 50 2 See PRECAUTIONS BEFORE STARTING OIL BURNERS and START UP on page 7 and burner figures on this page 3 All burner models shown are single stage THROTTLE 3 16 SEE TABLE FOR CORRECT SETTINGS RING HEAD HEAD ADJUSTMENT ADJUSTMENT SCREW HOWN AT M 2 A AIR TUBE 5 16 AIR SHUTTER ADJUSTMENT SCREW XL 2000 13 BURNER DATA BECKETT BURNERS FOR PACKAGED BOILERS ONLY BECKETT BECKETT FIRING OIL PUMP APPROXIMATE BURNER BURNER RATE ANGLE PRESSURE AIR SHUTTER APPROXIMATE STATI
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